Coated zeolite catalysts and use for hydrocarbon conversion

ABSTRACT

There is provided a coated zeolite catalyst in which the accessibility of the acid sites on the external surfaces of the zeolite is controlled and a process for converting hydrocarbons utilizing the coated zeolite catalyst. The zeolite catalyst comprises core crystals of a first zeolite and a discontinuous layer of smaller size second crystals of a second zeolite which cover at least a portion of the external surface of the first crystals The coated zeolite catalyst finds particular application in hydrocarbon conversion processes where catalyst activity in combination with zeolite structure are important for reaction selectivity, e.g., catalytic cracking, alkylation, disproportional of toluene, isomerization, and transalkylation reactions.

This application is a divisional of U.S. application Ser. No. 10/309,453filed Dec. 4, 2002 now U.S. Pat. No. 6,812,181; which is a divisional ofU.S. application Ser. No. 09/204,576, filed Dec. 3, 1998, now U.S. Pat.No. 6,504,074, issued Jan. 7, 2003, which claims priority to U.S.Provisional Patent Application No. 60/067,415, filed Dec. 3, 1997.

FIELD OF THE INVENTION

This invention relates to coated zeolite catalysts having controlledexternal surface acidity and the use of the coated zeolite catalysts inhydrocarbon conversion processes.

BACKGROUND OF THE INVENTION

Crystalline microporous molecular sieves, both natural and synthetic,have been demonstrated to have catalytic properties for various types ofhydrocarbon conversion processes. In addition, the crystallinemicroporous molecular sieves have been used as adsorbents and catalystcarriers for various types of hydrocarbon conversion processes, andother applications. These molecular sieves are ordered, porous,crystalline material having a definite crystalline structure asdetermined by x-ray diffraction, within which there are a large numberof smaller cavities which may be interconnected by a number of stillsmaller channels or pores. The dimensions of these channels or pores aresuch as to allow for adsorption of molecules with certain dimensionswhile rejecting those of large dimensions. The interstitial spaces orchannels formed by the crystalline network enable molecular sieves suchas crystalline silicates, aluminosilicates, crystalline silicoaluminophosphates, and crystalline aluminophosphates, to be used as molecularsieves in separation processes and catalysts and catalyst supports in awide variety of hydrocarbon conversion processes.

Zeolites are comprised of a lattice of silica and optionally aluminacombined with exchangeable cations such as alkali or alkaline earthmetal ions. Although the term “zeolites” includes materials containingsilica and optionally alumina, it is recognized that the silica andalumina portions may be replaced in whole or in part with other oxides.For example, germanium oxide, tin oxide, phosphorous oxide, and mixturesthereof can replace the silica portion. Boron oxide, iron oxide, galliumoxide, indium oxide, and mixtures thereof can replace the aluminaportion. Accordingly, the terms “zeolite”, “zeolites” and “zeolitematerial”, as used herein, shall mean not only materials containingsilicon and, optionally, aluminum atoms in the crystalline latticestructure thereof, but also materials which contain suitable replacementatoms for such silicon and aluminum, such as gallosilicates,silicoaluminophosphates (SAPO) and aluminophosphates (ALPO). The term“aluminosilicate zeolite”, as used herein, shall mean zeolite materialsconsisting essentially of silicon and aluminum atoms in the crystallinelattice structure thereof.

Within a pore of the zeolite, hydrocarbon conversion reactions such asparaffin isomerization, olefin skeletal or double bond isomerization,disproportionation, alkylation, and transalkylation of aromatics aregoverned by constraints imposed by the channel size of the zeolite.Reactant selectivity occurs when a fraction of the feedstock is toolarge to enter the pores to react; while product selectivity occurs whensome of the products can not leave the channels or do not subsequentlyreact. Product distributions can also be altered by transition stateselectivity in which certain reactions can not occur because thereaction transition state is too large to form within the pores. Shapeselectivity can also result from configuration constraints on diffusionwhere the dimensions of the molecule approach that of the pore.

Non-selective reactions on the external surface acid sites of zeolitesare usually not desirable because they are not subject to the shapeselective constraints imposed on those reactions occurring within thechannels of the zeolites and are often not desirable. For example, thesurface acid sites can adversely effect reactants entering the pores ofthe zeolite and products exiting the pores of the zeolite.

Various procedures have been prepared for limiting surface acidity ofthe zeolites. For example, the surface acidity of aluminosilicatezeolites can be reduced by dealumination of the zeolite surface.Techniques for the dealumination include hydrothermal treatment, mineralacid treatment with HCl, HNO₃, or H₂SO₄, and chemical treatment withSiCl₄ and EDTA. A problem associated with these procedures is that theycan degrade the zeolite crystals and/or cause the zeolite crystals tolose sorption capacity. Still further, dealumination can also reduce theoverall activity of the zeolite, which can result in reduced catalystactivity and/or activity maintenance.

Another procedure for limiting the surface acidity of zeolites, asdisclosed in U.S. Pat. No. 4,203,869, involves synthesizing anisocrystalline layer of aluminum-free zeolite over the surface of thezeolite.

The present invention is directed to coated zeolite catalysts and theuse of the coated zeolite catalysts in hydrocarbon conversion processes.

SUMMARY OF THE INVENTION

In accordance with the present invention, there are provided zeolitecatalysts having an external surface zeolite coating. The coated zeolitecatalysts comprise first crystals of a first zeolite and smaller sizesecond crystals of a second zeolite. The smaller size second crystalsprovide a coating on at least a portion of the external surface of thefirst crystals.

The coated zeolite catalysts of the present invention have enhancedperformance when utilized in hydrocarbon conversion processes. Thecoated zeolite catalysts of the present invention finds particularapplication in hydrocarbon conversion processes where catalyst acidityin combination with zeolite structure are important for reactionselectivity. Examples of such processes include catalytic cracking,alkylation, dealkylation, dehydrogenation, disproportionation, andtransalkylation reactions. The coated zeolite catalysts of the presentinvention also find application in other hydrocarbon conversionprocesses in which carbon containing compounds are changed to differentcarbon containing compounds. Examples of such processes includehydrocracking, isomerization, dewaxing, oligomerization, and reformingprocesses.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a SEM micrograph (20,000 times) of Catalyst A of Example 1

FIG. 2 is a SEM micrograph (10,000 times) of Catalyst C of Example 1

DETAILED DESCRIPTION OF THE INVENTION

The coated zeolite catalyst of the present invention will contain acoating of second crystals of a second zeolite having an averageparticle size that is smaller than the average particle size of thefirst crystals and which second crystals cover at least a portion of theexternal surface of the first crystals. The second crystals can growtogether and can form an overgrowth over the first crystals. By coatingthe first crystals with the second crystals, the accessibility ofreactants and products to the external surface acid sites of the firstzeolite is reduced.

The term “coating” as used in the specification and claims, means that adiscontinuous layer of second zeolite crystals formed-such as by beingdeposited or grown on and covering at least a portion of the externalsurface of the first zeolite crystals and having an average particlesize that is less than the average particle size of the first crystalssuch that the second zeolite crystals are non-continuous with the firstcrystals, i.e., the crystalline framework of the second zeolite crystalsis not part of or a continuation of the framework of the first zeolite.Hence, the layer deposited on the first zeolite crystals is notisocrystalline with the first zeolite crystals.

The average particle size of the second crystals will usually besubstantially less than the average particle size of first crystals,e.g., at least 50% less than the average particle size of the firstcrystals. In addition, the second crystals will usually not be incrystallographic alignment with each other. Furthermore, the secondcrystals will usually not be disposed concentrically or follow the samelongitudinal axis. Still further, the second zeolite crystals areusually not uniformly deposited on the first crystals.

Since the first crystals are larger than the second crystals, thesecrystals are sometimes referred to in the specification and claims ascore crystals. The structure type of the first zeolite will depend uponthe particular hydrocarbon process in which the coated zeolite catalystis used. For instance, if the intended use of the coated zeolitecatalyst is for selective toluene disproportionation, the first zeoliteis preferably an intermediate pore size zeolite such as a zeolite havingan MFI or MEL structure type. In addition, the core crystals can alsocomprise more than one zeolite. For example, the core crystals cancomprise two or more zeolites having different structure types,different compositions, or combinations thereof. The core crystals willpreferably have an average particle size of from about 0.1 to about 15microns. In some applications, the average particle size will preferablybe from about 1 to about 6 microns. In other applications such as thecracking of hydrocarbons, the preferred average particle size will befrom about 0.1 to about 3 microns.

The amount of core crystals present in the coated catalyst willgenerally be an amount in the range of from about 10 weight percent toabout 90 weight percent based on the total weight of zeolite present inthe coated catalyst. The amount of core crystals present in the coatedzeolite catalyst will usually be determined by the process in which thecatalyst is used.

The second crystals, which are sometimes referred to in thespecification and claims as coating crystals, will form a coating on atleast a portion of the external surface of the core crystals.Preferably, the coating will cover at least 50 percent of the outersurface of the first crystals and more preferably will cover at least 75percent of the external surface of the first crystals. In someapplications it may be desirable for the coating to reduce accessibilityof reactants to the acid sites on the external surface of the firstzeolite by covering at least 50 percent, even more preferably at least75 percent, and most preferably at least 90 percent of the acid sites.The coating will usually be non-uniform and may adhere to the surface ofthe core crystals. The average particle size of the coating crystalswill be smaller than the average particle size of the core crystals.Preferably, the coating crystals will have an average particle size ofless than 1 micron, more preferably from about 0.1 to about 0.5 micron.The structure type of the zeolite used to coat the core crystals willdepend upon the particular hydrocarbon process in which the coatedzeolite catalyst is used. For instance, if the intended use of thecoated zeolite catalyst is for toluene disproportionation and the corecrystals are an intermediate pore size zeolite having an MFI or MELstructure type, the coating crystals could comprise an intermediate poresize zeolite having less acidity than the core crystals. The coatingcrystals can also comprise more than one zeolite. For example, thecoating crystals can comprise two or more zeolites having differentstructure types, different compositions, or combinations thereof.

The coated zeolite catalyst may be incorporated with a binder materialresistant to the temperature and other conditions employed inhydrocarbon conversion processes such as metal oxides. The binder can beincorporated with the catalyst by mixing the binder with the catalystand then forming the mixture into the appropriate catalyst shape.Examples of suitable binder materials include non-zeolitic material suchas synthetic or naturally occurring substances such as clays, silicas,and/or metal oxides. Well known materials include silica, alumina,silica-alumina, magnesia, silica-magnesia, zirconia, silica-zirconia,silica-thoria, silica-beryllia, titania, silica-titania, ternarycompositions, such as silica-alumina-thoria, silica-alumina-zirconia,silica-alumina-magnesia and silica-magnesia-zirconia, alumina sols,hydrated alumina, and clays such as bentonite or kaolin. The binder isusually present in an amount of from about 5 to about 95 weight percentand preferably about 15 to about 85 weight percent, based on the weightof the catalyst.

The term “average particle size” as used herein, means the arithmeticaverage of the diameter distribution of the crystals on a volume basis.The “diameter” of the crystals will be the sum of the length anddiameters of crystals divided by 2.

The terms “acidity”, “lower acidity” and “higher acidity” as applied tozeolite are known to persons skilled in the art. The acidic propertiesof zeolite are well known. However, with respect to the presentinvention, a distinction must be made between acid strength and acidsite density. Acid sites of a zeolite can be a Bronsted acid or a Lewisacid. The density of the acid sites is important in determining theacidity of the zeolite. Factors directly influencing the acid strengthare (i) the chemical composition of the zeolite framework, i.e.,relative concentration and type of tetrahedral atoms, (ii) theconcentration of the extra-framework cations and the resultingextra-framework species, (iii) the local structure of the zeolite, e.g.,the pore size and the location, within the crystal or at/near thesurface of the zeolite, and (iv) the pretreatment conditions andpresence of co-adsorbed molecules. The amount of acidity is related tothe degree of isomorphous substitution provided, however, such acidityis limited to the loss of acid sites for a pure SiO₂ composition. Asused herein, the terms “acidity”, “lower acidity” and “higher acidity”refers to the concentration of acid sites irregardless of the strengthof such acid sites which can be measured by ammonia absorption.

Zeolites suitable for use as the first zeolite and second zeoliteinclude any of the naturally occurring or synthetic crystallinezeolites. Examples of these zeolites include large pore zeolites, mediumpore zeolites, and small pore zeolites. These zeolites and theirisotypes are described in “Atlas of Zeolite Structure Types”, eds. W. H.Meier, D. H. Olson and Ch. Baerlocher, Elsevier, Fourth Edition, 1996,which is hereby incorporated by reference. A large pore zeolitegenerally has a pore size of at least about 7 Å and includes LTL, VFI,MAZ, MEI, FAU, EMT, OFF, *BEA, and MOR structure type zeolites (IUPACCommission of Zeolite Nomenclature). Examples of large pore zeolites,include mazzite, offretite, zeolite L, VPI-5, zeolite Y, zeolite X,omega, Beta, ZSM-3, ZSM-4, ZSM-18, ZSM-20, SAPO-37, and MCM-22. Anintermediate pore size zeolite generally has a pore size from about 5 Åto about 7 Å and includes, for example, ZSM-48 type and MFI, MEL, MTW,EUO, MTT, HEU, FER, MFS, TON structure type zeolites (IUPAC Commissionof Zeolite Nomenclature). Examples of intermediate pore size zeolitesinclude ZSM-5, ZSM-12, ZSM-22, ZSM-23, ZSM-34, ZSM-35, ZSM-38, ZSM-48;ZSM-50; ZSM-57, silicalite, and silicalite 2. A small pore size zeolitehas a pore size from about 3 Å to about 5.0 Å and includes, for example,CHA, ERI, KFI, LEV, and LTA structure type zeolites (IUPAC Commission ofZeolite Nomenclature). Examples of small pore zeolites include ZK-4,SAPO-34, SAPO-35, ZK-14, SAPO-42, ZK-21, ZK-22, ZK-5, ZK-20, zeolite A,erionite, chabazite, zeolite T, gmelinite, ALPO-17, and clinoptilolite.

In general, the chemical formula of anhydrous crystallinemetallosilicate can be expressed in terms of moles as represented by theformula: M₂/_(n)O:W₂O₃:ZSiO₂, wherein M is selected from the groupconsisting of hydrogen, hydrogen precursors, monovalent, divalent andtrivalent cations and mixtures thereof; n is the valence of the cationand Z is a number of at least 2, preferably at least 3, said value beingdependent upon the particular type of zeolite, and W is a metal in theanionic framework structure of the zeolite such as aluminum, gallium,boron, iron, titanium, or mixtures thereof.

Generally, the first and second zeolites of the coated zeolite catalystcomprise compositions having the following molar relationship:X₂O_(3:):(n)YO₂,wherein X is a trivalent element, such as titanium, boron, aluminum,iron, and/or gallium, Y is a tetravalent element such as silicon, tin,and/or germanium, and n has a value of at least 1, said value beingdependent upon the particular type of zeolite and the trivalent elementpresent in the zeolite.

When the first zeolite has an intermediate pore size, the zeolitepreferably comprises a composition having the following molarrelationship:X₂O_(3:):(n)YO₂,wherein X is a trivalent element, such as aluminum, gallium, iron,boron, titanium, or mixtures thereof. Y is a tetravalent element such assilicon, tin, and/or germanium; and n has a value greater than 10,usually from about 20 to less than 20,000, more usually from 50 to2,000, said value being dependent upon the particular type of zeoliteand the trivalent element present in the zeolite.

As known to persons skilled in the art, the acidity of a zeolite can bereduced using many techniques. In addition, the acidity of a zeolite isdependent upon the form of the zeolite with the hydrogen form having thehighest acidity and other forms of the zeolite such as the sodium formhaving less acidity than the acid form. Accordingly, the mole ratios ofsilica to alumina and silica to gallia disclosed in the specificationand claims includes not only zeolites having the disclosed mole ratios,but also includes zeolites not having the disclosed mole ratios buthaving equivalent catalytic activity.

When the first zeolite is a gallosilicate intermediate pore sizezeolite, the zeolite preferably comprises a composition having thefollowing molar relationship:Ga₂O₃:ySiO₂wherein y is between about 20 and about 500, typically from 20 to 200.The zeolite framework may contain only gallium and silicon atoms or mayalso contain a combination of gallium, aluminum, and silicon.

When the first zeolite used in the coated zeolite catalyst is analuminosilicate zeolite, the silica to alumina mole ratio will usuallydepend upon the structure type of the zeolite and the particularhydrocarbon process in which the catalyst is utilized and is thereforenot limited to any particular ratio. Generally, however, and dependingon the structure type of the zeolite, the zeolite will have a silica toalumina mole ratio of at least 2:1 and in some instances from 4:1 toabout 7:1. For a number of zeolites, especially intermediate pore sizezeolites, the silica to alumina mole ratio will be in the range of fromabout 10:1 to about 1,000:1. When the catalyst is utilized in acidcatalyzed reactions such as cracking, the manufacture of paraxylene andbenzene by the disproportionation of toluene, the alkylation of benzeneor the like, the zeolite will be acidic and will preferably, when it isan intermediate pore size zeolite, have higher silica to alumina moleratios, e.g., 20:1 to about 200:1.

As previously stated, the structure type of the first zeolite willdepend on the particular hydrocarbon process in which the coated zeolitecatalyst is utilized. For instance, if the coated zeolite catalyst isused for the reforming of naphtha to aromatics, the zeolite type of thefirst zeolite will preferably be LTL (example Zeolite L) and have asilica to alumina ratio from 4:1 to about 7:1. If the coated zeolitecatalyst is used for xylene isomerization or the manufacture ofparaxylene and benzene by the disproportionation of toluene, the firstzeolite will preferably be an intermediate pore size zeolite, such as aMFI structure type (example ZSM-5). If the coated zeolite catalyst is tobe used for cracking paraffins, the preferred pore size and structuretype will depend on the size of the molecules to be cracked and thedesired product. The selection of the first zeolite structure type forhydrocarbon conversion processes is known to persons skilled in the art.

The preferred structure type of the second zeolite will depend on thestructure type of the first zeolite and the particular hydrocarbonprocess in which the coated zeolite catalyst is utilized. For instance,if the coated zeolite catalyst is used for xylene isomerization or themanufacture of paraxylene and benzene by the disproportionation oftoluene, and the first zeolite is an intermediate pore size zeolite,such as a zeolite having a MFI structure type (example ZSM-5), thesecond zeolite will preferably be a low acidity intermediate pore sizezeolite such as a MFI or MEL structure type zeolite. If the coatedzeolite catalyst is to be used for cracking paraffins, the preferredpore size and structure type of the second zeolite will depend on thesize of the molecules to be cracked and the desired product.

When the second zeolite is aluminosilicate zeolite, the silica toalumina mole ratio of the second zeolite, will usually depend upon thestructure type of the first zeolite and particular hydrocarbon processin which the catalyst is utilized and is therefore not limited to anyparticular ratio. Generally, however, and depending on the structuretype of the zeolite, the silica to alumina ratio will be at least 2:1.In applications where the aluminosilicate zeolite is an intermediatepore size zeolite and low acidity is desired, the second zeolitepreferably has a silica to alumina mole ratio greater than the silica toalumina mole ratio of the first zeolite, and more preferably is greaterthan 200:1. The second zeolite can also have higher silica to aluminamole ratios, e.g., 300:1, 500:1, 1,000:1, etc. In certain applications,the second zeolite can be a Silicalite i.e., the second zeolite is a MFIstructure type substantially free of alumina or Silicalite 2, i.e., thesecond zeolite is a MEL structure type substantially free of alumina.The pore size of the second zeolite will usually be a pore size thatdoes not adversely restrict access of the desired molecules of thehydrocarbon feedstream to the catalytic phase of the first zeolite. Forinstance, when the materials of the feedstream which are to be convertedby the first zeolite have a size from 5 Å to 6.8 Å, the second zeolitewill preferably be a large pore zeolite or an intermediate pore sizezeolite. However, the pore size of the second zeolite may be smallerthan the materials in the feed stream and in some instances this mayeven be desirable. In these instances, access to the first zeolitecrystals is through the macro porosity of the coated catalyst.

The coated zeolite catalysts are preferably prepared by converting asilica coating on the core crystals to the second zeolite coatingcrystals. This procedure involves first synthesizing the core crystalsof the first zeolite. Processes for preparing the first zeolite areknown to persons skilled in the art. For example, aluminosilicate MFIstructure type zeolites can be made using the procedure described inU.S. Pat. No. 3,702,886.

Next, a silica-bound zeolite can be prepared by mixing a mixturecomprising the core crystals, a silica gel or sol, water, and optionallyan extrusion aid until a homogeneous composition in the form of anextrudable paste develops. The silica used in preparing the silica boundzeolite aggregate is preferably a silica sol and can contain variousamounts of trivalent metal oxides such as alumina. The amount of zeolitein the dried extrudate at this stage will preferably range from about 20to 90% by weight, more preferably from about 50 to 80% by weight, withthe balance being primarily silica, e.g. about 20 to 50% by weightsilica.

The resulting paste can then molded, e.g., extruded, and cut into smallstrands, e.g., 2 mm diameter extrudates, which are dried at 100-150° C.for a period of 4-12 hours and then calcined in air at a temperature offrom about 400° C. to 550° C. for a period of from about 1 to 10 hours.

Optionally, the silica-bound aggregate can be made into a very smallparticles which have application in fluid bed processes such ascatalytic cracking. This preferably involves mixing the zeolite with asilica containing matrix solution so that an aqueous solution of zeoliteand silica binder is formed which can be sprayed dried to result insmall fluidizable silica-bound aggregate particles. Procedures forpreparing such aggregate particles are known to persons skilled in theart. An example of such a procedure is described by Scherzer(Octane-Enhancing Zeolitic FCC Catalysts, Julius Scherzer, MarcelDekker, Inc. New York, 1990). The fluidizable silica-bound aggregateparticle's, like the silica bound extrudates described above, would thenundergo the final step described below to convert the silica binder to asecond zeolite.

Next, the silica present in the silica-bound zeolite is converted to asecond zeolite. The silica of the silica bound zeolite can be convertedto the second zeolite coating crystals by first aging the silica boundzeolite in an appropriate aqueous solution at elevated temperature.Next, the contents of the solution and the temperature at which theaggregate is aged are selected to convert the amorphous silica binderinto the desired second zeolite. The newly-formed second zeolite isproduced as crystals on the first zeolite. After formation of thecrystals, the resulting aggregate can be broken apart such as bycrushing, to form the coated zeolite. Alternatively, the silica boundzeolite aggregate can be broken apart prior to conversion of the silicato the second zeolite. The second crystals can grow together and caneven form an over-growth on the first crystals. The coated zeolitecatalyst may consist essentially of the first crystals of the firstzeolite and second crystals of the second zeolite.

After forming the coated zeolite, one or more additional coatings ofsmaller size second zeolite crystals can also be applied to the coatedzeolite using, for example, the procedure described above. These zeolitecoating crystals can be a structure type, composition, or combinationsthereof, that are different from the first zeolite or second zeolite.The coated zeolite with the additional coating can be bound by thebinder materials previously described.

The coated zeolite may be further ion exchanged as is known in the arteither to replace at least in part the original metals present in thezeolite with a different cation, e.g. a Group IB to VIII of the PeriodicTable metal such as nickel, copper, zinc, calcium or rare earth-metals,or to provide a more acidic form of the zeolite by exchange of alkalimetal with intermediate ammonium cation followed by calcination of theammonium form to provide the acidic hydrogen form. The acidic form maybe readily prepared by ion exchange using a suitable reagent such asammonium nitrate solution followed by calcination to remove ammonia andform the acidic hydrogen form. Ion exchange is preferably conductedafter formation of the coated zeolite catalyst. Particularly preferredcations are those which render the material catalytically active,especially for certain hydrocarbon conversion reactions. These includehydrogen, rare earth metals, and one or more metals of Groups IIA, IIIA,IVA, VA, VIA, VIIA, VIII, IB, IIB, IIIB, IVB, and VB of the PeriodicTable of the Elements. Examples of suitable metals include Group VIIImetals (i.e., Pt. Pd, Ir, Rh, Os, Ru, Ni, Co and Fe), Group IVA metals(i.e., Sn and Pb), Group VB metals (i.e., Sb and Bi), and Group VIIBmetals (i.e., Mn, Tc and Re). Noble metals (i.e., Pt, Pd, Ir, Rh, Os andRu) are sometimes preferred. Reference to the metals is intended toencompass such metal or metals in the elemental state (i.e., zerovalence) or some other catalytically active form such as an oxide,sulfide, halide, carboxylate, and the like.

The coated zeolite catalyst of the present invention can be used inprocessing hydrocarbon feedstocks. Hydrocarbon feed-stocks containcarbon compounds and can be from many different sources, such as virginpetroleum fractions, recycle petroleum fractions, tar sand oil, and, ingeneral, can be any carbon containing fluid susceptible to zeoliticcatalytic reactions. Depending on the type of processing the hydrocarbonfeed is to undergo, the feed can contain metal or can be free of metals.Also, the feed can also have high or low nitrogen or sulfur impurities.

The conversion of hydrocarbon feeds can take place in any convenientmode, for example, in a fluidized bed, moving bed, or fixed bed reactorsdepending on the types of process desired.

The coated zeolite catalyst of the present invention by itself or incombination with one or more catalytically active substances can be usedas a catalyst or support for a variety of organic, e.g., hydrocarboncompound, conversion processes. Examples of such conversion processesinclude, as non-limiting examples, the following:

-   -   (A) The catalytic cracking of a naphtha feed to produce light        olefins. Typical reaction conditions include from about 500° C.        to about 750° C., pressures of subatmospheric or atmospheric,        generally ranging up to about 10 atmospheres (gauge) and        residence time (volume of the catalyst feed rate) from about 10        milliseconds to about 10 seconds.    -   (B) The catalytic cracking of high molecular weight hydrocarbons        to lower weight hydrocarbons. Typical reaction conditions for        catalytic cracking include temperatures of from about 400° C. to        about 700° C., pressures of from about 0.1 atmosphere (bar) to        about 30 atmospheres, and weight hourly space velocities of from        about 0.1 to about 100 hr⁻¹.    -   (C) The transalkylation of aromatic hydrocarbons in the presence        of polyalkylaromatic hydrocarbons. Typical reaction conditions        include a temperature of from about 200° C. to about 500° C., a        pressure of from about atmospheric to about 200 atmospheres, a        weight hourly space velocity of from about 1 to about 100 hr⁻¹        and an aromatic hydrocarbon/polyalkylaromatic hydrocarbon mole        ratio of from about 1/1 to about 16/1.    -   (D) The isomerization of aromatic (e.g., xylene) feedstock        components. Typical reaction conditions for such include a        temperature of from about 230° C. to about 510° C., a pressure        of from about 0.5 atmospheres to about 50 atmospheres, a weight        hourly space velocity of from about 0.1 to about 200 and a        hydrogen/hydrocarbon mole ratio of from about 0 to about 100.    -   (E) The dewaxing of hydrocarbons by selectively removing        straight chain paraffins. The reaction conditions are dependent        in large measure on the feed used and upon the desired pour        point. Typical reaction conditions include a temperature between        about 200° C. and 450° C., a pressure up to 3,000 psig and a        liquid hourly space velocity from 0.1 to 20.    -   (F) The alkylation of aromatic hydrocarbons, e.g., benzene and        alkylbenzenes, in the presence of an alkylating agent, e.g.,        olefins, formaldehyde, alkyl halides and alcohols having 1 to        about 20 carbon atoms. Typical reaction conditions include a        temperature of from about 100° C. to about 500° C., a pressure        of from about atmospheric to about 200 atmospheres, a weight        hourly space velocity, of from about 1 hr⁻¹ to about 100 hr⁻¹        and an aromatic hydrocarbon/alkylating agent mole ratio of from        about 1/1 to about 20/1.    -   (G) The alkylation of aromatic hydrocarbons, e.g., benzene, with        long chain olefins, e.g., C₁₄ olefin. Typical reaction        conditions include a temperature of from about 50° C. to about        200° C., a pressure of from about atmospheric to about 200        atmospheres, a weight hourly space velocity of from about 2 hr⁻¹        to about 2000 hr⁻¹ and an aromatic hydrocarbon/olefin mole ratio        of from about 1/1 to about 20/1. The resulting product from the        reaction are long chain alkyl aromatics which when subsequently        sulfonated have particular application as synthetic detergents;    -   (H) The alkylation of aromatic hydrocarbons with light olefins        to provide short chain alkyl aromatic compounds, e.g., the        alkylation of benzene with propylene to provide cumene. Typical        reaction conditions include a temperature of from about 10° C.        to about 200° C., a pressure of from about 1 to about 30        atmospheres, and an aromatic hydrocarbon weight hourly space        velocity (WHSV) of from 1 hr⁻¹ to about 50 hr⁻¹;    -   (I) The hydrocracking of heavy petroleum feedstocks, cyclic        stocks, and other hydrocrack charge stocks. The zeolite catalyst        will contain an effective amount of at least one hydrogenation        component of the type employed in hydrocracking catalysts.    -   (J) The alkylation of a reformate containing substantial        quantities of benzene and toluene with fuel gas containing short        chain olefins (e.g., ethylene and propylene) to produce mono-        and dialkylates. Preferred reaction conditions include        temperatures from about 100° C. to about 250° C., a pressure of        from about 100 to about 800 psig, a WHSV-olefin from about 0.4        hr⁻¹ to about 0.8 hr⁻¹, a WHSV-reformate of from about 1 hr⁻¹ to        about 2 hr⁻¹ and, optionally, a gas recycle from about 1.5 to        2.5 vol/vol fuel gas feed.    -   (K) The alkylation of aromatic hydrocarbons, e.g., benzene,        toluene, xylene, and naphthalene, with long chain olefins, e.g.,        C₁₄ olefin, to produce alkylated aromatic lube base stocks.        Typical reaction conditions include temperatures from about        100° C. to about 400° C. and pressures from about 50 to 450        psig.    -   (L) The alkylation of phenols with, olefins or equivalent        alcohols to provide long chain alkyl phenols. Typical reaction        conditions include temperatures from about 100° C. to about 250°        C., pressures from about 1 to 300 psig and total WHSV of from        about 2 hr⁻¹ to about 10 hr⁻¹.    -   (M) The conversion of light paraffins to olefins and/or        aromatics. Typical reaction conditions include temperatures from        about 425° C. to about 760° C. and pressures from about 10 to        about 2000 psig.    -   (N) The conversion of light olefins to gasoline, distillate and        lube range hydrocarbons. Typical reaction conditions include        temperatures of from about 175° C. to about 375° C. and a        pressure of from about 100 to about 2000 psig.    -   (O) Two-stage hydrocracking for upgrading hydrocarbon streams        having initial boiling points above about 200° C. to premium        distillate and gasoline boiling range products or as feed to        further fuels or chemicals processing steps. The first stage        would be the coated zeolite catalyst comprising one or more        catalytically active substances, e.g., a Group VIII metal, and        the effluent from the first stage would be reacted in a second        stage using a second zeolite, e.g., zeolite Beta, comprising one        or more catalytically active substances, e.g., a Group VIII        metal, as the catalyst. Typical reaction conditions include        temperatures from about 315° C. to about 455° C., a pressure        from about 400 to about 2500 psig, hydrogen circulation of from        about 1000 to about 10,000 SCF/bbl and a liquid hourly space        velocity (LHSV) of from about 0.1 to 10;    -   (P) A combination hydrocracking/dewaxing process in the presence        of the coated zeolite catalyst comprising a hydrogenation        component and a zeolite such as zeolite Beta. Typical reaction        conditions include temperatures from about 350° C. to about 400°        C., pressures from about 1400 to about 1500 psig, LHSVs from        about 0.4 to about 0.6 and a hydrogen circulation from about        3000 to about 5000 SCF/bbl.    -   (Q) The reaction of alcohols with olefins to provide mixed        ethers, e.g., the reaction of methanol with isobutene and/or        isopentene to provide methyl-t-butyl ether (MTBE) and/or t-amyl        methyl ether (TAME). Typical conversion conditions include        temperatures from about 20° C. to about 200° C., pressures from        2 to about 200 atm, WHSV (gram-olefin per hour gram-zeolite)        from about 0.1 hr⁻¹ to about 200 hr⁻¹ and an alcohol to olefin        molar feed ratio from about 0.1/1 to about 5/1.    -   (R) The disproportionation of aromatics, e.g., the        disproportionation toluene to make benzene and paraxylene.        Typical reaction conditions include a temperature of from about        200° C. to about 760° C., a pressure of from about atmospheric        to about 60 atmosphere (bar), and a WHSV of from about 0.1 hr⁻¹        to about 30 hr⁻¹.    -   (S) The conversion of naphtha (e.g., C₆-C₁₀) and similar        mixtures to highly aromatic mixtures. Thus, normal and slightly        branched chained hydrocarbons, preferably having a boiling range        above about 40° C., and less than about 200° C., can be        converted to products having a substantial higher octane        aromatics content by contacting the hydrocarbon feed with the        coated zeolite at a temperature in the range of from about        400° C. to 600° C. preferably 480° C. to 550° C. at pressures        ranging from atmospheric to 40 bar, and liquid hourly space        velocities (LHSV) ranging from 0.1 to 15.    -   (T) The adsorption of alkyl aromatic compounds for the purpose        of separating various isomers of the compounds.    -   (U) The conversion of oxygenates, e.g., alcohols, such as        methanol, or ethers, such as dimethylether, or mixtures thereof        to hydrocarbons including olefins and aromatics with reaction        conditions including a temperature of from about 275° C. to        about 600° C., a pressure of from about 0.5 atmosphere to about        50 atmospheres and a liquid hourly space velocity of from about        0.1 to about 100.    -   (V) The oligomerization of straight and branched chain olefins        having from about 2 to about 5 carbon atoms. The oligomers which        are the products of the process are medium to heavy olefins        which are useful for both fuels, i.e., gasoline or a gasoline        blending stock, and chemicals. The oligomerization process is        generally carried out by contacting the olefin feedstock in a        gaseous state phase with the coated zeolite catalyst at a        temperature in the range of from about 250° C. to about 800° C.,        a LHSV of from about 0.2 to about 50 and a hydrocarbon partial        pressure of from about 0.1 to about 50 atmospheres. Temperatures        below about 250° C. may be used to oligomerize the feedstock        when the feedstock is in the liquid phase when contacting the        coated zeolite catalyst. Thus, when the olefin feedstock        contacts the catalyst in the liquid phase, temperatures of from        about 10° C. to about 250° C. may be used.    -   (W) The conversion of C₂ unsaturated hydrocarbons (ethylene        and/or acetylene) to aliphatic C₆₋₁₂ aldehydes and converting        said aldehydes to the corresponding C₆₋₁₂ alcohols, acids, or        esters.

In general, the catalytic conversion conditions over the coated zeolitecatalyst include a temperature of from about 100° C. to about 760° C., apressure of from about 0.1 atmosphere (bar) to about 200 atmospheres(bar), a weight hourly space velocity of from about 0.08 hr⁻¹ to about2,000 hr⁻¹.

Although many hydrocarbon conversion processes prefer that the secondzeolite crystals have lower acidity to reduce undesirable reactionsexternal to the first zeolite crystals, some processes may prefer thatthe second crystals have higher acidity, e.g., cracking reactions.

Processes that also find particular application using the coated zeolitecatalyst of the present invention are those where two or more reactionsare taking place within the coated zeolite catalyst. This catalyst wouldcomprise two different zeolites that are each separately tailored topromote or inhibit different reactions. A process using such a catalystbenefits not only from reduced non-selective surface acidity, but from atailored catalyst.

Examples of preferred coated zeolite catalysts include the following:

-   -   1. A coated zeolite catalyst comprising an acidic second zeolite        having cracking activity and an acidic first zeolite having        acidic activity which is less than the acidic activity of the        second zeolite and a smaller pore size than the second zeolite.        The coated zeolite catalyst finds application in cracking larger        size molecules and isomerizing the smaller cracked molecules.        Examples of suitable second zeolites include Beta, Mordenite and        the like. Examples of suitable first zeolites are ZSM-5, ZK-5,        ZSM-11 and the like.    -   2. A coated zeolite catalyst comprising an acidic first zeolite        having a large or intermediate pore size zeolite with cracking        activity and an acidic second zeolite having smaller pore size        than the second zeolite and having cracking activity. An example        of a suitable first zeolite is ZSM-5 and an example of a        suitable second zeolite is ZK-5. The coated zeolite catalyst        finds particular application in cracking larger size molecules        and further cracking the smaller cracked molecules to produce        ethylene.    -   3. A coated zeolite catalyst comprising one zeolite (either the        first or second zeolite) that has reduced acid activity and        optionally contains a hydrogenation/dehydrogenation metal and        another zeolite which has medium strength acidic activity and        optionally a hydrogenation/dehydrogenation metal. The pore size        of the zeolites will depend upon the type of process in which        the catalyst is utilized. For example, the catalyst can be        utilized in a combined xylene isomerization/ethylbenzene        dealkylation process wherein the ethylbenzene is dealkylated to        benzene and ethylene and isomers of xylenes are isomerized to        equilibrium amounts. For use in such a process, the first        zeolite will preferably be a large or intermediate pore size        zeolite and the second zeolite will also preferably be a large        or intermediate pore size zeolite.    -   4. A coated zeolite catalyst comprising a first acidic zeolite        and a second zeolite which has little or no acidic activity. The        pore size of the zeolites will depend on the type of process in        which the catalyst is utilized. For example, if the catalyst is        to be used in the disproportionation of aromatics, e.g.,        manufacture of benzene and paraxylene by the disproportionation        of toluene, the first zeolite will preferably have an        intermediate pore size and have acid activity and the second        zeolite can be selected to control accessibility of reactants or        products exiting the pores of the zeolite to the acid sites on        the external surfaces of the first zeolite.

The coated zeolite catalyst of the present invention has particularapplication in the vapor phase disproportionation of toluene. Such vaporphase disproportionation comprises contacting toluene underdisproportionation conditions with the coated zeolite catalyst to yielda product mixture which comprises a mixture of unreacted (unconverted)toluene, benzene and xylene. In the more preferred embodiment, thecoated zeolite catalyst is first selectivated prior to use in thedisproportionation process to enhance conversion of toluene to xyleneand to maximize the catalyst selectivity towards the production ofparaxylene. Processes for selectivating the catalyst are known topersons skilled in the art. For instance, selectivation can beaccomplished by treating the surface of the catalyst with compounds ofphosphorous and/or metal oxides such as magnesium, antimony, andmanganese.

Selectivation may be also accomplished by exposing the catalyst in areactor bed to a thermally decomposable organic compound, e.g., toluene,at a temperature in excess of the decomposition temperature of saidcompound, e.g. from about 480° C. to about 650° C., more preferably 540°C. to about 650° C., at a WHSV in the range of from about 0.1 to 20 lbsof feed per pound of catalyst per hour, at a pressure in the range offrom about 1 to 100 atmospheres, and in the presence of 0 to about 2moles of hydrogen, more preferably from about 0.1 to about 2 moles ofhydrogen per mole of organic compound, and optionally in the presence of0-10 moles of nitrogen or another inert gas per mole of organiccompound. This process is conducted for a period of time until asufficient quantity of coke has been deposited on the catalyst surface,generally at least about 2% by weight and more preferably from about 8to about 40% by weight of coke. In a preferred embodiment, such aselectivation process is conducted in the presence of hydrogen in orderto prevent rampant formation of coke on the catalyst.

Selectivation of the catalyst can also be accomplished by treating thecatalyst with a selectivation agent such as an organosilicon compound.Examples of organosilicon compounds include polysiloxane includingsilicones, a siloxane, and a silane including disilanes andalkoxysilanes.

Silicone compounds that find particular application can be representedby the formula:

wherein R₁ is hydrogen, fluoride, hydroxy, alkyl, aralkyl, alkaryl orfluoro-alkyl. The hydrocarbon substituents generally contain from 1 to10 carbon atoms and preferably are methyl or ethyl groups. R₂ isselected from the same group as R₁, and n is an integer of at least 2and generally in the range of 2 to 1000. The molecular weight of thesilicone compound employed is generally between 80 and 20,000 andpreferably 150 to 10,000. Representative silicone compounds includeddimethylsilicone, diethylsilicone, phenylmethylsilicone, methylhydrogensilicone, ethylhydrogensilicone, phenylhydrogensilicone,methyethylsilicone, phenylethylsilicone, diphenylsilicone, methyltrifluoropropylsilicone, ethyltrifluoropropylsilicone, tetrachlorophenylmethyl silicone, tetrachlorophenylethyl silicone, tetrachlorophenylhydrogen silicone, tetrachlorophenylphenyl silicone,methylvinylsilicone and ethylvinylsilicone. The silicone compound neednot be linear but may be cyclic as for examplehexamethylcyclotrisiloxane, octamethylcyclotetrasiloxane, hexaphenylcyclotrisiloxane and octaphenylcyclotetrasiloxane. Mixtures of thesecompounds may also be used as well as silicones with other functionalgroups.

Useful siloxanes or polysiloxanes include as non-limiting exampleshexamethylcyclotrisiloxane, octamethylcyclotetrasiloxane, decamethylcyclopentasiloxane, hexamethyldisiloxane, octamethy-trisiloxane,decamethyltetrasiloxane, hexaethylcyclotrisiloxane, octaethylcyclotetrasiloxane, hexaphenylcyclotrisiloxane and octaphenylcyclotetrasiloxane.

Useful silanes, disilanes, or alkoxysilanes include organic substitutedsilanes having the general formula:

wherein R is a reactive group such as hydrogen, alkoxy, halogen,carboxy, amino, acetamide, trialkylsilyoxy R₁, R₂ and R₃ can be the sameas R or can be an organic radical which may include alkyl of from 1 to40 carbon atoms, alkyl or aryl carboxylic acid wherein the organicportion of the alkyl contains 1 to 30 carbon atoms and the aryl groupcontains 6 to 24 carbon which may be further substituted, alkylaryl andarylalkyl groups containing 7 to 30 carbon atoms. Preferably, the alkylgroup for an alkyl silane is between 1 and 4 carbon atoms in chainlength.

When used the vapor phase disproportionation of toluene, the catalystpreferably comprises MFI-type zeolite core crystals having an averageparticle size from about 2 to about 6 microns, a silica to alumina moleratio of from about 20 to about 200:1, preferably, 25:1 to about 120:1,and second crystals having a MFI or MEL structure type and an averageparticle size of less than about 0.5 micron, and more preferably lessthan 0.1 micron having a alumina to silica mole ratio in excess of about200:1 to about 10,000:1 and most preferably greater than 500:1.

Once the catalyst has been selectivated to the desired degree, reactorselectivation conditions are changed to disproportionation conditions.Disproportionation conditions include a temperature between about 400°C. and 600° C., more preferably between about 425° C. and 510° C., at ahydrogen to toluene mole ratio of from 0 to about 10, preferably betweenabout 0.1 and 5 and more preferably from about 0.1 to 1, at a pressurebetween about 1 atmosphere and 100 atmospheres and utilizing WHSV ofbetween about 0.5 and 50

The coated zeolite catalyst of the present invention also findsparticular application as a catalyst in a process for isomerizing one ormore xylene isomers in a C₈ aromatic feed to obtain ortho-, meta-, andpara-xylene in a ratio approaching the equilibrium value. In particular,xylene isomerization is used in conjunction with a separation process tomanufacture para-xylene. For example, a portion of the para-xylene in amixed C₈ aromatics stream may be recovered using processes known in theart, e.g., crystallization, adsorption, etc. The resulting stream isthen reacted under, xylene isomerization conditions to restore ortho-,meta-, and paraxylenes to a near equilibrium ratio. Ethylbenzene in thefeed is either removed from the stream or is converted during theprocess to xylenes or to benzene which are easily separated bydistillation. The isomerate is blended with fresh feed and the combinedstream is distilled to remove heavy and light by-products. The resultingC₈ aromatics stream is then recycled to the separation device to repeatthe cycle.

It is important that xylene isomerization catalysts produce a nearequilibrium mixture of xylenes and it is also desirable that thecatalyst convert ethylbenzene with very little net loss of xylenes. Thecoated zeolite catalyst finds particular application in this regard. Thesilica to alumina mole ratios of the first zeolite and second zeolitecan be selected to balance xylene isomerization and ethylbenzenedealkylation while minimizing undesirable side reactions. When used forxylene isomerization, the first zeolite will usually be analuminosilicate zeolite having a silica to alumina mole ratio from 70:1to about 700: or a gallosilicate having a silica to gallia mole ratiofrom about 24:1 to about 500:1 and the second zeolite will usually bealuminosilicate zeolite having a silica to alumina mole ratio greaterthan 200:1 or a gallosilicate having a silica to gallia mole ratiogreater than 100:1. If the feed stream also contains ethylbenzene, thecoated catalyst will also usually contain one or more metals such asplatinum. The process is carried out by contacting a C₈ aromatic streamcontaining one or more xylene isomers, ethylbenzene, or mixturesthereof, under isomerization conditions with the coated zeolitecatalyst. Preferably, at least 30% of the ethylbenzene is converted.

In the vapor phase, suitable isomerization conditions include atemperature in the range 250° C.-600° C., preferably 300° C.-550° C., apressure in the range 0.5-50 atm abs, preferably 10-25 atm abs, and aweight hourly space velocity (WHSV) of 0.1 to 100, preferably 0.5 to 50.Optionally, isomerization in the vapor phase is conducted in thepresence of 3.0 to 30.0 moles of hydrogen per mole of alkylbenzene. Ifhydrogen is used, the metal components of the catalyst preferablyinclude 0.1 to 2.0 wt. % of a hydrogenation/dehydrogenation componentselected from Group VIII of the Periodic Table of Elements, especiallyplatinum, palladium, or nickel. By Group VIII metal component, it ismeant the metals and as well as their compounds such as oxides andsulfides.

The coated zeolite catalysts of the present invention are especiallyuseful as a catalyst in a process for cracking a naphtha feed, e.g., C₄⁺ naphtha feed, particularly a C₄ ⁻290° C. naphtha feed to produce lowmolecular weight olefins, e.g., C₂ through C₄ olefins, particularlyethylene and propylene. Such a process is preferably carried out bycontacting the naphtha feed at temperatures ranging from 500° C. toabout 750° C., more preferably 550° C. to 675° C., at a pressure fromsubatmospheric up to 10 atmospheres, but preferably from about 1atmosphere to about 3 atmospheres.

The coated zeolite catalysts of the present invention are especiallyuseful as a catalyst in the transalkylation of polyalkylaromatichydrocarbons. Examples of suitable polyalkylaromatic hydrocarbonsinclude di-, tri-, and tetra-alkyl aromatic hydrocarbons, such asdiethylbenzene, triethylbenzene, diethylmethylbenzene (diethyl-toluene),diisopropyl-benzene, triisopropylbenzene, diisopropyltoluene,dibutylbenzene, and the like. Preferred polyalkylaromatic hydrocarbonsare the dialkyl benzenes. Particularly preferred polyalkyl-aromatichydrocarbons are diisopropylbenzene and diethylbenzene.

The transalkylation process will preferably have a molar ratio ofaromatic hydrocarbon to polyalkylaromatic hydrocarbon of preferably fromabout 0.5:1 to about 50:1, and more preferably from about 2:1 to about20:1. The reaction temperature will preferably range from about 340° C.to 500° C., and the pressure will be preferably in the range of about 50psig to 1,000 psig, preferably 300 psig to 600 psig. The weight hourlyspace velocity will range from about 0.1 to 10.

The coated zeolite catalysts find particular application in processesfor converting aromatic compounds from paraffins or olefins. Example ofsuitable paraffins or olefins including aliphatic hydrocarbonscontaining 2 to 12 carbon atoms. The hydrocarbons may be straight chain,open or cyclic and may be saturated or unsaturated. Example ofhydrocarbons include ethane, ethylene, propane, propylene, n-butane,n-butenes, isobutane, isobutene, and straight- and branch-chain andcyclic pentanes, pentenes, hexanes, and hexenes.

The aromatization conditions include a temperature of from about 200° C.to about 700° C., a pressure of from about 0.1 atmosphere to about 60atmospheres, a weight hourly space velocity (WHSV) of from about 0.1 toabout 400 and a hydrogen/hydrocarbon mole ratio of from about 0 to about20.

The coated zeolite catalyst used in the aromatization process preferablycomprises core crystals of an intermediate pore size zeolite such a MFItype zeolite (example ZSM-5), and coating crystals of a intermediatepore size such as a MFI or MEL structure type. The catalyst preferablycontains gallium. Gallium may be incorporated into the during synthesisof the catalyst or it may be exchanged or impregnated or otherwiseincorporated into the zeolite after synthesis. Preferably 0.05 to 10 wt.percent, and most preferably 0.1 to 2.0 wt. percent gallium isassociated with the coated zeolite catalyst. The gallium can beassociated with the first zeolite, second zeolite, or both zeolites.

The coated zeolite catalyst also finds, particular application inprocesses for the production of xylenes by catalytic methylation oftoluene in the presence of the coated zeolite catalyst. In carrying outthe methylation process, the catalyst and reactants can be heated toreaction temperature separately or together. Reaction temperatures arefrom about 300° C. to about 700° C. and preferably about 400° C. toabout 700° C. The reaction is preferably carried out at a pressure fromabout 1 to 1000 psig, a weight hourly space velocity of between about 1and about 2000, a molar ratio of methylating agent to toluene betweenabout 0.05 and about 5 and a weight hourly space velocity of betweenabout 1 and about 200 and preferably between about 5 and about 150weight of charge per weight of catalyst per hour. The coated zeolitecatalyst can be selectivated to improve its paraxylene selectivity.Selectivation can be accomplished by the techniques used to enhance itsparaxylene selectivity for use in the disproportionation of toluene.

Typical methylating agents include methanol, dimethylether,methylchloride, methylbromide and dimethylsulfide. One skilled in theart will know that other methylating agents may be employed in theprocess of this invention based on the description provided therein.Preferred methylating agents are methanol and dimethylether. Methanol ismost preferred.

The methylation process can be carried out as a batch type,semi-continuous or continuous operation utilizing a fixed or moving bedcatalyst system. Multiple injection of the methylating agent may beemployed.

Toluene and the methylating agent are usually premixed and fed togetherinto the reaction vessel to maintain the desired ratio between them withno local concentration of either reactant to disrupt reaction kinetics.Individual feeds can be employed, however, if care is taken to insuregood mixing of the reactant vapors in the reaction vessel. Instantaneousconcentration of methylating agent can be kept low by staged additionsthereof. By staged additions, toluene/methylating agent concentrationscan be maintained at optimum levels to give good toluene conversions.Hydrogen gas can be supplied to the reaction as an anticoking agent anddiluent.

The following examples illustrate the invention:

EXAMPLE 1

I. Catalyst A

Catalyst A comprised 70 wt. % ZSM-5 core crystals (average particle sizeof 3.0 microns) having a silica to alumina mole ratio of about 66:1 and30 wt. % silicalite coating crystals. The catalyst was prepared by firstmixing the ZSM-5 core crystals with amorphous silica and then extrudingthe mixture into a silica bound extrudate. Next, the silica binder ofthe extrudate was converted to the second zeolite by aging the aggregateat elevated temperatures in an aqueous solution containing a templateand hydroxy ions sufficient to covert the silica to the binder crystals.The resulting product was then washed, dried, calcined, ion exchangedinto the hydrogen form, and crushed. FIG. 1 is a SEM micrograph ofCatalyst A.

II. Catalyst B

Catalyst B comprised about 70 wt. % MFI structure type zeolite corecrystals (average particle size of 3.0 microns) having a silica togallia mole ratio of about 100:1, 30 wt. % MFI structure type bindercrystals having a silica to gallia mole ratio of about 900:1, and about0.49 wt. % platinum. The catalyst was prepared by first mixing the corecrystals, platinum salt, and amorphous silica containing a trace amountof gallia and then extruding the mixture into a silica bound extrudate.Next, the silica binder of the extrudate was converted to the zeolitebinder by aging the extrudate at elevated temperatures in an aqueoussolution containing a template and hydroxy ions sufficient to covert thesilica to the binder crystals. The resulting zeolite bound zeolite wasthen washed, dried, calcined, ion exchanged into the hydrogen form, andcrushed.

III. Catalyst C

Catalyst C comprised zeolite Beta coated with ZSM-48. The catalyst wasprepared by first forming silica bound extrudates containing zeolitebeta (sodium form and a silica to alumina mole ratio of 12.4). Theextrudates were formed as follows:

Components Used For Preparation Quantity (Grams) Beta crystals 300.00SiO₂ gel (Aerosil 300) 11.5 Silica sol (Nyacol 2034 DI) 346.2 Water 70.7Extrusion Aid (Methocel) 2.3

The components were mixed in the order listed. A plastic extrudabledough was obtained. The dough was extruded into approximately 2 mmextrudates. The extrudates were dried overnight at 120° C. and thencalcined for 8 hours at 510° C.

Composition of the calcined silica-bound extrudate (on a dry basis):Beta=70.0 wt. %SiO₂=30 wt. %

The silica bound extrudates were converted to zeolite beta bound byZSM-48 as follows:

Components Used For Preparation Quantity, (Grams) Component No. NaOH0.577 1 1,6 diammino hexane 3.50 2 Water 22.52 3 Rinse Water 10.01 4Silica bound beta 26.18 5

A solution comprising Components 1, 2, and 3 was prepared at roomtemperature and transferred to 100 ml autoclave. Component 4 was used totransfer the solution to the contents of the autoclave. The contents ofthe autoclave were stirred and finally 26.18 grams of beta crystals(saturated with 23.6 wt. % water) were added to the contents of theautoclave. The molar composition of the synthesis mixture was:0.71Na₂O/3R/10SiO₂/217H₂O

Crystallization was carried out by heating in 2 hours to 150° C. andthen maintaining the temperature at 150° C. for 35 hours. The resultingproduct was washed with 400 ml of water. The conductivity of the lastwash water was 25 μS/cm. The product was dried overnight at 120° C.,calcined in air at 500° C. for 16 hours, and crushed to break apart theextrudate.

The product was analyzed by XRD and SEM with the following results:

-   -   XRD: Showed typical patterns for zeolite beta and ZSM-48 with        excellent crystallinity.    -   SEM: 10,000 times Micrograph (FIG. 2) shows the Beta crystals        are coated with newly formed crystals having a submicron size.        Core crystals=70 wt. % Coating crystals=30 wt. %

Toluene methylation tests were carried out using Catalyst A, Catalyst B,and Catalyst C. An amount of 1.0 gram of each catalyst was loaded into atubular reactor. The catalysts tested were in powdered form (<100 mesh).The results are shown in Table I. All performance data are the averageof the run.

TABLE I Catalyst A Catalyst B Catalyst C Temp., ° C. 551 449 350Pressure, psia 17.9 16 365 WHSV (^(g)feed/^(g)cat^(h)) 20.6 10.6 7.6Time on Stream, hr 17 4 22 H₂/methanol/toluene 1.5/0.33/1.00.47/0.17/1.00 0/0.11/1.00 (mole:mole:mole) Product Distribution (wt.%)* C⁶⁻ 3.3 3.2 ** Benzene 2.0 1.8 5.1 Xylenes 79.6 75.0 67.6 EB 0.1 0.10.2 Trimethyl benzene 0.1 0.3 6.8 Methl ethyl benzene 9.9 7.3 ** C₇₊ andA₉₊ (other) 5.0 12.2 20.2 100.0 99.9 99.9 Performance Data Toluene Conv.% 15.2 13.5 11.4 MeOH Conv. % 97.5 99.7 99.9 p-Xylene in xylenes 52.034.6 26.8 *Excluding water and unreacted feed **Not determined

EXAMPLE 2

Preparation of platinum-containing zeolite coated MFI type galliumsilicate catalyst.

MFI type gallosilicate crystals (4 micron size spherical crystals andSiO₂/Ga₂O₃=48) were formed into silica bound extrudates or follows:

Components Used For Preparation Quantity (Grams) Component No. SilicaSol (Nalcoag 1034) 49.44 1 Silica gel (Aerosil 300) 4.72 2 H₂PtCl₆.6H₂O0.93 3 Water 11.07 Rinse Water 3.27 4 Gallium silicate MFI Crystals49.86 5 Extrusion aid (hydroxypropyl 0.34 6 methyl cellulose

The components were mixed in a dough mixer in the order Indicated. Afteradding the extrusion aid, and mixing for about 15 minutes, a dough wasobtained. The dough was divided into several portions and dried in anoven at 120° C. for 16 hours. The dried portions were crushed, and thencalcined at 490° C. for 24 hours in air.

The silica coated core crystals were converted into zeolite boundzeolite as follows:

Components Used For Preparation Quantity (Grams) Component A NaOHpellets (98.7%) 1.162 Water 16.08 Rinse Water (A) 17.06 Ga₂O₃ (99.995%)0.144 Component B Tetrapropylammonium bromide 7.96 Water 16.16 RinseWater (B) 15.64 Component C Silica coated gallosilicate MFI 60.07

Component A was prepared by combining the ingredients and then boilinguntil a clear solution was obtained. The solution was cooled to roomtemperature and water loss due to boiling was corrected. Component B wasprepared at room temperature. Component B was added to Component A usingrinse water (2) to form D. Component C was added to a 300 ml stainlesssteel autoclave and D was added to the autoclave using rinse water (1).

The molar composition of the synthesis mixture was:0.47/Na₂O/1.00TPABr/0.025Ga₂O₃/10SiO₂/150H₂O

The autoclave was heated from room temperature to 150° C. in 2 hours andmaintained at this temperature for 40 hours. The resulting product waswashed 5 times at 60° C. with 1800 ml of water. The conductivity of thelast wash water was 50 μS/cm. The product was dried at 120° C., calcinedin air at 500 for 12 hours, and crushed.

The product was analyzed by XRD and SEM with the following results:

-   -   XRD: Excellent crystallinity    -   SEM: 5 micron size spherical crystals coated with coffin type        crystals. No visible amorphous silica. The coating crystals had        the following dimensions: 0.50-0.75 μm length, about 0.2 μm        width, and about 0.4 thick.

Simultaneous xylene isomerization and ethylbenzene reduction reactionswere conducted using the coated catalyst as prepared above by passing anartificial feed through a fixed bed reactor. The feed contained C₈-C₁₀nonaromatics (0.6%), toluene (1.3%), ethylbenzene (15.6%), p-xylene(1.4%), m-xylene (65.1%), o-xylene (16.0%) and A9+ (<0.1%). The catalystwas pretreated in H₂ for about 1 h at 775° F. and 250 psig.Subsequently, the feed was introduced into the reactor. After about 112hours on stream, the run conditions were changed. A summary of theconditions and results are shown in Table II:

TABLE II Condition No. 1 2 Temperature (° F.) 775 792 HC Inlet PartialPressure (psi) 118 76 H₂ Inlet Partial Pressure (psi) 118 151 WHSV(#/#/Hr) 10 10 Hours On-Oil 112 148 % EB reacted 72.3 73.9 Ring Loss (%of feed aromatic 0.9 1.0 rings) Xylenes Loss (% of feed xylenes) 4.5 3.6PX approach to equilibrium (%)* 100.7 100.4

The percent, % EB reacted, was determined by the formula: % EB Conv=100×[EB in−EB out] divided by EB in; Aromatics ring loss % was determined bythe formula: 100× (moles of aromatics in feed−moles of aromatics inproduct)/(moles of aromatics in feed). Loss of xylenes was determined bythe formula: 100× (moles of xylenes in feed−moles of xylenes inproduct)/(moles of xylenes in feed) and PX approach to equilibrium wasdetermined by the formula: (Product PX/Xs−Feed PX/Xs)/(EquilibriumPX/Xs−FeedPX/Xs)×100.

EXAMPLE 3

A coated zeolite catalyst was prepared which comprised about 70 wt. %ZSM-5 core crystals (average particle size of 3.0 microns) having asilica to alumina mole ratio of about 70:1 and 30 wt. % silicalitecoating crystal. The catalyst was prepared by first mixing the ZSM-5core crystals with amorphous silica and then extruding the mixture intoa silica bound extrudate. Next, the silica binder of the extrudate wasconverted to the second zeolite by aging the aggregate at elevatedtemperatures in an aqueous solution containing a template and hydroxyions sufficient to covert the silica to the binder crystals. Theresulting product was then washed, dried, calcined, ion exchanged intothe hydrogen form, and crushed. An additional coating of silicalite wasapplied to the zeolite coated product by first mixing the coated ZSM-5core crystals with amorphous silica and then extruding the mixture intoa silica bound extrudate. Next, the silica binder of the extrudate wasconverted to coating silicalite by aging the aggregate at elevatedtemperatures in an aqueous solution containing a template and hydroxyions sufficient to covert the silica to the binder crystals. Theresulting product was then washed, dried, calcined, ion exchanged intothe hydrogen form, and crushed.

The zeolite coated zeolite was tested for the disproportionation oftoluene. The catalyst was evaluated under 4 separate test conditions asshown in Table III below. On-oil catalyst performance for the catalystis shown in Table IV.

TABLE III On-Oil Conditions Feed = Toluene Test 1 Test 2 Test 3 Test 4Temperature (° F.) 834 875 834 854 Feed Part. Press (psi) 94 94 94 94 H₂Part. Press (psi) 187 187 187 187 WHSV (#/#/#) 3.0 3.0 2.1 2.1

TABLE IV On-Oil Catalyst Performance Test 1 Test 2 Test 3 Test 4Conversion 30.7 41.5 36.9 42.7 % PX in MX + OX + PX 24.3 24.3 24.2 24.2BZ 12.6 17.2 15.1 17.8 Xylene 16.1 21.1 18.3 21.6 C₅ ⁻ 0.4 0.9 0.6 1.0A₉ ⁺ 1.4 1.9 1.7 2.0 EB 0.1 0.3 0.2 0.4

The results show that the catalyst had good activity for toluenedisproportionation.

EXAMPLE 4

Preparation of MFI Core Crystals Coated with MFI Crystals

A zeolite coated zeolite was prepared which comprised ZSM-5 corecrystals having a silica to alumina mole ratio of about 75 and aparticle size of 3 microns which were coated with silicalite.

The catalyst was prepared by mixing the ZSM-5 core crystals with silicaand then extruding the mixture to form a silica-bound extrudate. Theextrudate was crushed, calcined, and dried. The product comprised ZSM-5core crystals coated with silica. The silica coated core crystals wereconverted into MFI core crystals coated with silicalite as follows:

Component Ingredients Quantity in Grams 1 NaOH (98.7%%) 1.311 H₂O 25.092 TPABr 8.05 H₂O 24.95 3 Silica coated MFI- 59.77 crushed, calcined,dried 4 Rinse Water 10.61 5 Rinse Water 29.38

Components 1 and 2 were prepared at room temperature. Component 2 wasadded to Component 1 using rinse water 5 to form A. Component 3 wastransferred to a 300 ml stainless steel autoclave and then A was addedto the contents of the autoclave using rinse water 4.

The synthesis liquor had the following molar composition:0.47Na₂O/TPABr/10SiO₂/168H₂O

The autoclave was heated to 150° C. in 2 hours and kept at 150° C. for40 hours. The product was then washed 5 times with 1800 ml of water. Theconductivity of the last wash water was less than 50 μS/cm. The productwas dried at 120° C. and calcined at 500° C. for 12 hours.

-   -   XRD: MFI present and crystallinity good.    -   SEM: Showed the presence of zeolite core crystals coated with        small zeolite crystals that were partially intergrown. Some free        crystals having a length of 0.5 μm were also present.

A toluene methylation test was carried out using the catalyst asprepared above. An amount of approximately 1.0 gram of the catalyst inpowdered form (40/60 mesh) was loaded into a tubular reactor. Theresults are shown in Table V.

TABLE V Temp., ° C. 450 450 Pressure, psia 15 15 WHSV(^(g)feed/^(g)cat^(h)) 14 14 Time on Stream, hr 1 3 methanol/toluene0.99 0.99 (mole/mole) Product Yields* Benzene 7.0 2.4 Xylene 68.4 71.7Trimethyl benzene 9.7 11.2 Methyl ethyl benzene 6.1 7.2 Performance DataToluene Conv. % 46.8 45.5 MeOH Conv. % 100.0 100.0 p-Xylene in xylenes28.0 30.9 *Product Yield = moles formed/moles toluene reacted

EXAMPLE 5

Preparation of MFI Core Crystals Coated with MEL Crystals

A zeolite coated zeolite catalyst was prepared which comprised ZSM-5core crystals having a silica to alumina mole ratio of about 75 and aparticle size of about 3 microns which were coated with silicalite 2.

The coated catalyst was prepared by mixing the ZSM-5 core crystals withsilica and then extruding the mixture to form a silica-bound extrudate.The extrudate was crushed, calcined, and dried. The product comprisedZSM-5 core crystals coated with silica. The silica coated core crystalswere converted into zeolite coated zeolite as follows:

Component Ingredients Quantity in Grams 1 NaOH (98.6%%) 0.97 H₂O 22.78 2Tetrabutylammonium 7.65 hydroxide H₂O 22.01 3 Silica coated MFI- 54.63crushed, calcined, and dried 4 Rinse Water 19.36

Components 1 and 2 were prepared at room temperature. Component 2 wasadded to Component 1 using rinse water 4 to form A. Component 3 wastransferred to a 300 ml stainless steel autoclave and A was added to thecontents of the autoclave.

The autoclave was heated to 150° C. in 2 hours and kept at 150° C. for40 hours. The product was then washed 5 times with 1800 ml of water. Theconductivity of the last wash water was less than 50 μS/cm. The productwas dried at 120° C. and calcined at 500° C. for 12 hours.

-   -   SEM: Showed the presence of zeolite core crystals coated with        small zeolite crystals that were intergrown.

A toluene methylation test was carried out using the catalyst preparedas described above. An amount of approximately 1.0 gram of the catalystin powdered form (40/60 mesh) was loaded into a tubular reactor. Theresults are shown in Table VI.

TABLE VI Temp., ° C. 450 450 Pressure, psia 15 15 WHSV (g feed/g cat h)14 14 Time on Stream, hr 1 3 Methanol/toluene 0.99 0.99 (mole/mole)Product Yields* Benzene 7.7 2.5 Xylene 72.0 78.5 Trimethyl benzene 7.68.6 Methyl ethyl benzene 6.6 6.6 Performance Data Toluene Conv. % 40.837.1 MeOH Conv. % 100.0 100.0 p-Xylene in xylenes 31.8 33.4 *ProductYield = moles formed/moles toluene reacted

1. A process for converting hydrocarbons comprising contacting ahydrocarbon feedstream under hydrocarbon conversion conditions with acoated zeolite catalyst, said zeolite catalyst being selected from thegroup consisting of: (I) A zeolite catalyst comprising: (a) firstcrystals of a first acidic zeolite having catalytic activity; (b) adiscontinuous layer of second crystals of a second zeolite having lessacidity than said first zeolite and a structure type that is the same assaid first zeolite and said second crystals have an average particlesize less than the average particle size of said first crystals coveringat least a portion of the external surface of said first crystals; and(c) non-zeolitic binder present in an amount of at least about 15 weightpercent based on the weight of the zeolite catalyst; (II) A zeolitecatalyst comprising: (a) first crystals of a first acidic zeolite havingcatalytic activity; and, (b) a discontinuous layer of second crystals ofa second zeolite and a third zeolite said second crystals having anaverage particle size less than the average particle size of said firstcrystals covering at least a portion of the external surface of saidfirst crystals, and said third zeolite has a structure type,composition, or both that is different from said second zeolite; (III) Azeolite catalyst comprising: (a) first crystals of a first acidiczeolite having catalytic activity; (b) a discontinuous layer of secondcrystals of a second zeolite having a structure type that is differentfrom said first zeolite and said second crystals have an averageparticle size less than the average particle size of said first crystalscovering at least a portion of the external surface of said firstcrystals; (c) non-zeolitic binder present in an amount of at least about15 weight percent based on the weight of the zeolite catalyst; and, (IV)Mixtures thereof.
 2. The process recited in claim 1 wherein said secondcrystals cover at least 50 percent of the external surface acid sites ofsaid first crystals.
 3. The process recited in claim 2, wherein saidsecond crystals have an average particle size that is at least 50% lessthan the average particle size of said first crystals.
 4. The processrecited in claim 3 wherein said second crystals are grown together. 5.The process recited in claim 4, wherein the accessibility of reactantsto the external acid sites of the first zeolite is reduced by about atleast 75 percent.
 6. The process recited in claim 3, wherein said firstcrystals have an average particle size of from about 0.1 to about 15microns.
 7. The process recited in claim 6, wherein said second crystalshave an average particle size of less than 1 micron.
 8. The processrecited in claim 7, wherein said first zeolite and said second zeoliteare independently a structure type selected from the group consisting ofOFF, BEA, MAZ, MEI, FAU, EMT, LTL, MOR, MFI, MFS, MEL, MTW, MTT, FER,EUO, TON, CHA, ERI, KFI, LEV, and LTA.
 9. The process recited in claim1, wherein the hydrocarbon conversion is selected from the groupconsisting of cracking of hydrocarbons, isomerization of alkylaromatics, transalkylation of aromatics, alkylation of aromatics,reforming of naphtha to aromatics, conversion of paraffins and/orolefins to aromatics, conversion of oxygenates to hydrocarbon products,cracking of naphtha to light olefins, and dewaxing of hydrocarbons. 10.The process recited in claim 9, wherein said hydrocarbon conversion isshape selective.
 11. The process of claim 9, wherein said hydrocarbonconversion is carried out at conditions comprising a temperature of from100° C. to about 760° C., a pressure of 0.1 atmosphere to 100atmospheres, a weight hourly space velocity of from about 0.08 hr⁻¹ toabout 200 hr⁻¹.
 12. The process recited in claim 11, wherein the poresize of said first zeolite is larger than the pore size of said secondzeolite.
 13. The process recited in claim 9, wherein the pore size ofsaid first zeolite is smaller than the pore size of said second zeolite.14. The process recited in claim 9, wherein said first zeolite andsecond zeolite are intermediate pore size zeolites.
 15. The processrecited in claim 14, wherein said first zeolite and said second zeoliteare aluminosilicate zeolites or gallium silicate zeolites.
 16. Theprocess recited in claim 15, wherein said second zeolite is analuminosilicate zeolite having a silica to alumina mole ratio greaterthan about 200:1.
 17. The process recited in claim 16, wherein saidfirst zeolite is an aluminosilicate zeolite having a silica to aluminamole ratio of from about 20:1 to about 200:1.
 18. The process recited inclaim 1, wherein the hydrocarbon conversion is isomerizing a hydrocarbonfeed containing an aromatic C₈ stream comprising, xylene isomers or amixture of xylene isomers and ethylbenzene.
 19. The process recited inclaim 18, wherein said coated zeolite catalyst further comprises acatalytically active metal.
 20. The process recited in claim 1, whereinthe hydrocarbon conversion is the cracking hydrocarbon compounds.